Selectively expandable screen for a resource exploration and recovery system

ABSTRACT

A selectively expandable screen system including a tubular having an outer surface and an inner surface defining a flow path. A screen assembly is mounted at the outer surface of the tubular. The screen assembly is formed from a compressible metal material. A selectively releasable compression device is coupled to the screen assembly. The selectively releasable compression device selectively maintains the compressible metal material in a compressed configuration.

BACKGROUND

In the resource exploration and recovery industry, tubulars are run into boreholes for the purpose of extracting formation fluids. Often times, a tubular may support one or more expandable seal members or packers. The packers, when activated, may separate the borehole into one or more production zones. An inflow device may be arranged on the tubular at each zone. A screen may be provided at the inflow device to filter formation fluids entering into the tubular. In some cases, expandable screens are employed. Expandable screens may be formed from synthetic material that engages with side walls of the borehole. The synthetic material has a limited operating temperature, burst rating and collapse rating. Therefore, the art would appreciate an expandable screen that may withstand higher temperatures and pressures.

SUMMARY

Disclosed is a selectively expandable screen system including a tubular having an outer surface and an inner surface defining a flow path. A screen assembly is mounted at the outer surface of the tubular. The screen assembly is formed from a compressible metal material. A selectively releasable compression device is coupled to the screen assembly. The selectively releasable compression device selectively maintains the compressible metal material in a compressed configuration.

Also disclosed is a resource exploration and recovery system including a first system, and a second system coupled to the first system through one or more tubulars. At least one of the one or more tubulars includes an outer surface and an inner surface defining a flow path, and a screen assembly mounted at the outer surface of the tubular. The screen assembly is formed from a compressible metal material. A selectively releasable compression device is coupled to the screen assembly. The selectively releasable compression device selectively maintains the compressible metal material in a compressed configuration.

Further disclosed is a method of deploying a screen formed from a metal material mounted to an outer surface of a tubular. The method includes compressing the metal material toward the outer surface of the tubular, restraining the metal material with a selectively releasable compression device, moving the screen into a selected position, and releasing the selectively releasable compression device allowing the metal material to expand radially outwardly of the outer surface.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

FIG. 1 depicts a resource exploration and recovery system including a selectively expandable screen, in accordance with an aspect of an exemplary embodiment;

FIG. 2 depicts a cross-sectional view of the selectively expandable screen of FIG. 1, in accordance with an aspect of an exemplary embodiment;

FIG. 3 depicts a cross-sectional view of a selectively expandable screen, in accordance with an aspect of an exemplary embodiment, in a run-in configuration;

FIG. 4 depicts the selectively expandable screen of FIG. 3 being deployed;

FIG. 5 depicts a cross-sectional view of a selectively expandable screen, in accordance with another aspect of an exemplary embodiment;

FIG. 6 depicts a cross-sectional view of the selectively expandable screen of FIG. 5 after being deployed;

FIG. 7 depicts a cross-sectional view of a selectively expandable screen prior to being compressed, in accordance with an aspect of an exemplary embodiment; and

FIG. 8 depicts a cross-sectional view of the selectively expandable screen of FIG. 7 after being compressed.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

A resource exploration and recovery system, in accordance with an exemplary embodiment, is indicated generally at 10, in FIG. 1. Resource exploration and recovery system 10 should be understood to include well drilling operations, resource extraction and recovery, CO₂ sequestration, and the like. Resource exploration and recovery system 10 may include a first system 14 which, in some environments, may take the form of a surface system 16 operatively and fluidically connected to a second system 18 which, in some environments, may take the form of a downhole system. First system 14 may include a control system 23 that may provide power to, monitor, communicate with, and/or activate one or more downhole operations as will be discussed herein. Surface system 16 may include additional systems such as pumps, fluid storage systems, cranes and the like.

Second system 18 may include a tubular string 30 formed from a plurality of tubulars, one of which is indicated at 32 that is extended into a wellbore 34 formed in formation 36. Wellbore 34 includes an annular wall 38 which may be defined by a surface of formation 36, or a casing tubular (not shown). A first expandable member which may take the form of a first packer 44 is arranged on tubular 32. First packer 44 may be selectively expanded into contact with annular wall 38. A second expandable member which may take the form of a second packer 46 is arranged on tubular 32 spaced from first packer 44 along tubular string 30. First and second packers 44 and 46 may collectively define a first zone 48, a second zone 49 and a third zone 50 along tubular string 30. The number, size and location of each zone 48-50 may vary.

In accordance with an aspect of an exemplary embodiment, second system 18 includes a selectively expandable screen system 60 coupled to tubular 32 at second zone 49. It should be understood that additional selectively expandable screen systems may be arranged in first and third zones 48 and 50 or in second zone 49. Referring to FIG. 2, selectively expandable screen system 60 includes a tubular 70 having an outer surface 72 and an inner surface 74 that defines a flow path 76. A screen assembly 80 is provided at outer surface 72.

Screen assembly 80 is formed from a compressible metal material 84. in an embodiment, compressible metal material 84 is resiliently compressible. That is, after being compressed, and after being released, screen assembly 80 returns to an uncompressed state due to intrinsic material properties of compressible metal material 84. in an embodiment, compressible metal material 84 may take the form of intermeshed metal fibers (not separately labeled). Once compressed, compressible metal material 84 may be secured by a selectively releasable compression device 94. In an embodiment, selectively releasable compression device 94 may take the form of a plurality of wires, one of which is indicated at 100.

In accordance with an aspect of an exemplary embodiment, plurality of wires 100 are made from a degradable material (not separately labeled) that may degrade when exposed to a selected fluid, for example, fluid in wellbore 34. The fluid may take the form of formation fluids or, fluids that are introduced from first system 14. In another embodiment, plurality of wires 100 may be frangible. Referring to FIG. 3 -4, tubular 70 may be formed from an expandable material. An expansion tool 106 may be directed into flow path 76 toward selectively expandable screen system 60 as shown in FIG. 3. A tapered end 108 of expansion tool 106 may be guided into tubular 70. Expansion tool 106 drives tubular 70 radially outwardly, causing plurality of wires 100 to sever or break, thereby releasing compressible metal material 84 as shown in FIG. 4, Compressible metal material 84 resiliently expands into contact with annular wall 38.

Reference will now follow to FIGS. 5 and 6 with continued reference to FIG. 1 in describing a selectively expandable screen system 130 in accordance with another aspect of an exemplary embodiment. Selectively expandable screen system 130 includes a tubular 134 having an outer surface 136 and an inner surface 138 that defines a flow path 140. A screen assembly 144 is arranged at outer surface 136. Screen assembly 144 is formed from a compressible metal material 148. In an embodiment, compressible metal material 148 is resiliently compressible. That is, after being compressed, and after being released, screen assembly 144 returns to an uncompressed state due to intrinsic material properties of compressible metal material 148. In an embodiment, compressible metal material 84 may take the form of intermeshed metal fibers (not separately labeled).

In accordance with an aspect of an exemplary embodiment, a selectively releasable compression member 160 maintains compressible metal material 148 in a compressed state as shown in FIG. 5. Selectively releasable compression member 160 may take the form of a tubular member 161 formed from a degradable material 162. Degradable material 162 may degrade when exposed to a selected fluid, for example, fluid in wellbore 34. The fluid may take the form of formation fluids or, fluids that are introduced from first system 14, Tubular member 161 is configured to degrade after a selected time period, thereby releasing compressible metal material 148. Compressible metal material 148 resiliently expands into contact with annular wall 38 as shown in FIG. 6.

Reference will now follow to FIGS. 7 and 8 in describing a method of compressing compressible metal material 148 in accordance with an exemplary aspect. Compressible metal material 148 is positioned on outer surface 136 of tubular 134 as shown in FIG. 7. Tubular 134 and compressible metal material 148 are inserted into a compression tool 170. Specifically, tubular 134 and compressible metal material 148 are inserted into a tapered or conical end 173 of compression tool 170. Tubular 134 and compressible metal material 148 are shifted towards a compression portion 176 having a selected diameter. Tubular 134 and compressible metal material 148 may then be inserted into selectively releasable compression member 160. It should be understood that compression tool 170 may also be employed to compress compressible metal material 84 of selectively expandable screen system 60.

It should be understood that the exemplary embodiments describe a selectively deployable screen formed from a compressible metal material. The compressible metal material may be selectively deployed through the use of degradable materials or tools designed for the purpose. The compressible metal material may provide an increased operating temperatures and burst ratings over those achieve by expandable screen assemblies formed from synthetic materials.

Set forth below are some embodiments of the foregoing disclosure:

Embodiment 1: A selectively expandable screen system comprising a tubular having an outer surface and an inner surface defining a flow path, a screen assembly mounted at the outer surface of the tubular, the screen assembly being formed from a compressible metal material, and a selectively releasable compression device coupled to the screen assembly, the selectively releasable compression device selectively maintaining the compressible metal material in a compressed configuration.

Embodiment 2: The selectively expandable screen system according to any prior embodiment, wherein the selectively releasable compression device comprises a plurality of wires extending about the tubular and the compressible metal material.

Embodiment 3: The selectively expandable screen system according to any prior embodiment, wherein the plurality of wires are formed from a degradable material.

Embodiment 4: The selectively expandable screen system according to any prior embodiment, wherein the selectively releasable compression device comprises a tubular.

Embodiment 5: The selectively expandable screen system according to any prior embodiment, wherein the tubular is formed from a degradable material.

Embodiment 6: The selectively expandable screen system according to any prior embodiment, wherein the compressible metal material comprises a plurality of intermeshed metal fibers.

Embodiment 7: A resource exploration and recovery system comprising a first system, a second system coupled to the first system through one or more tubulars, at least one of the one or more tubulars comprising an outer surface and an inner surface defining a flow path, a screen assembly mounted at the outer surface of the tubular, the screen assembly being formed from a compressible metal material, and a selectively releasable compression device coupled to the screen assembly, the selectively releasable compression device selectively maintaining the compressible metal material in a compressed configuration.

Embodiment 8: The resource exploration and recovery system according to any prior embodiment, wherein the selectively releasable compression device comprises a plurality of wires extending about the tubular and the compressible metal material.

Embodiment 9: The resource exploration and recovery system according to any prior embodiment, wherein the plurality of wires are formed from a degradable material.

Embodiment 10: The resource exploration and recovery system according to any prior embodiment, wherein the selectively releasable compression device comprises a tubular.

Embodiment 11: The resource exploration and recovery system according to any prior embodiment, wherein the tubular is formed from a degradable material.

Embodiment 12: The resource exploration and recovery system according to any prior embodiment, wherein the compressible metal material comprises a plurality of intermeshed metal fibers.

Embodiment 13: A method of deploying a screen formed from a metal material mounted to an outer surface of a tubular, the method comprising compressing the metal material toward the outer surface of the tubular, restraining the metal material with a selectively releasable compression device, moving the screen into a selected position, and releasing the selectively releasable compression device allowing the metal material to expand radially outwardly of the outer surface.

Embodiment 14: The method of any prior embodiment, wherein releasing the selectively releasable compression device includes degrading the selectively releasable compression device.

Embodiment 15: The method of any prior embodiment, wherein releasing the selectively releasable compression device includes breaking one or more retaining wires.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).

The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti -corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.

While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. 

What is claimed is:
 1. A selectively expandable screen system comprising: a tubular having an outer surface and an inner surface defining a flow path; a screen assembly mounted at the outer surface of the tubular, the screen assembly being formed from a compressible metal material; and a selectively releasable compression device coupled to the screen assembly, the selectively releasable compression device selectively maintaining the compressible metal material in a compressed configuration.
 2. The selectively expandable screen system according to claim 1, wherein the selectively releasable compression device comprises a plurality of wires extending about the tubular and the compressible metal material.
 3. The selectively expandable screen system according to claim 2, wherein the plurality of wires are formed from a degradable material.
 4. The selectively expandable screen system according to claim 1, wherein the selectively releasable compression device comprises a tubular.
 5. The selectively expandable screen system according to claim 4, wherein the tubular is formed from a degradable material.
 6. The selectively expandable screen system according to claim 1, wherein the compressible metal material comprises a plurality of intermeshed metal fibers.
 7. A resource exploration and recovery system comprising: a first system; a second system coupled to the first system through one or more tubulars, at least one of the one or more tubulars comprising: an outer surface and an inner surface defining a flow path; a screen assembly mounted at the outer surface of the tubular, the screen assembly being formed from a compressible metal material; and a selectively releasable compression device coupled to the screen assembly, the selectively releasable compression device selectively maintaining the compressible metal material in a compressed configuration.
 8. The resource exploration and recovery system according to claim 7, wherein the selectively releasable compression device comprises a plurality of wires extending about the tubular and the compressible metal material.
 9. The resource exploration and recovery system according to claim 8, wherein the plurality of wires are formed from a degradable material.
 10. The resource exploration and recovery system according to claim 7, wherein the selectively releasable compression device comprises a tubular.
 11. The resource exploration and recovery system according to claim 10, wherein the tubular is formed from a degradable material.
 12. The resource exploration and recovery system according to claim 7, wherein the compressible metal material comprises a plurality of intermeshed metal fibers.
 13. A method of deploying a screen formed from a metal material mounted to an outer surface of a tubular, the method comprising: compressing the metal material toward the outer surface of the tubular; restraining the metal material with a selectively releasable compression device; moving the screen into a selected position; and releasing the selectively releasable compression device allowing the metal material to expand radially outwardly of the outer surface.
 14. The method of claim 13, wherein releasing the selectively releasable compression device includes degrading the selectively releasable compression device.
 15. The method of claim 13, wherein releasing the selectively releasable compression device includes breaking one or more retaining wires. 